Needles for use with tufting machines

ABSTRACT

Needle assemblies for tufting machines in which reciprocable tufting needles each have substantially parallel depending complementary shank or leg portions defining a needle eye which can be opened and closed by relative movement of said shank or leg portions. Various eye opening means are disclosed as for example, stationary and rotatable internal cams, linearly movable mounting members from which said shanks or legs depend, and arcuately movable mounting members all of which are designed to open and close the needle eyes in unison to receive and/or release the yarn during the tufting operation.

United States Patent Spanel et al.

[111 3,757,715 [45 Sept. 11,1973

NEEDLES FOR USE WITH TUFTING MACHINES Inventors: Abram N. Spanel, 344 Stockton St.,

Princeton, NJ. 08540; John L. Schwartz, Hightstown, NJ.

Assignee: said Spanel, by said Schwartz Filed: Apr. 9, 1971 Appl. No.: 132,812

Related US. Application Data Division Of SB I'. N O; 836,399, June 25, 1969, Pat. N6. 3,670,672.

US. Cl. 112/221, 112/79 R, 112/222, 66/119 Int. Cl. D05b 85/00 Field of Search 112/221, 222225, 112/79 R, 79 A, 266;66/116, 117,119, 98

References Cited UNITED STATES PATENTS H1867 Miller et al. 66/116 100,112 2/1870 Boone 112/224 607,253 7/1898 Lyons 66/116 X 2,790,313 4/1957 Shccler 66/98 3,258,938 7/1966 Hofmann 66/119 Primary Examiner-James R. Boler Att0rney-Virgil E. Woodcock et al.

Needle assemblies for tufting machines in which recip- ABSTRACT rocable tufting needles each have substantially parallel depending complementary shank or leg portions defining a needle eye which can be opened and closed by relative movement of said shank or leg portions. Various eye opening means are disclosed as for example, stationary and rotatable internal cams, linearly movable mounting members from which said shanks or legs depend, and arcuately movable mounting members all of which are designed to open and close the needle eyes in unison to receive and/or release: the yarn during the tufting operation.

18 Claims, 33 Drawing Figures E EB 3; 757, 71

SHEET 1 BF 6 PATENTED I 73 3" 7 l 5 SHEET 5 BF //0C //0D //0c [mp i v i am 9' L L Y FIG. 24 FIG. 25

FIG. 27 Fl(; 28

NEEDLES FOR USE WITH TUFTING MACHINES This is a division of application Ser. No. 836,399 filed June 25, 1969, now US. Pat. No. 3,670,672.

CROSS-REFERENCE TO RELATED APPLICATION BACKGROUND OF THE INVENTION In general and in some respects, the present invention is in the nature of modifications of or improvements upon tufting machines such as shown in the aforesaid Spanel and Brennan application and in Spanel and Barton U.S. Pat. No. 3,387,577.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1, schematically and partly in section, illustrates various components of a basic mechanism for cutting, feeding and applying bits to a backing to form U-tufts;

FIG. 2 is adetail view showing in side elevation the bit-threading position of a tufting needle of split-eye usable in FIG. 1; 1

FIGS. 3 and 4 are-detail views showing in front and side elevation respectively, the threaded tufting needle of FIG. 2;

FIG. 5 is a detail view showinga modification bit-stop arrangement of FIG. '1;

FIGS. 6 and 7 are details views, in front and side elevation respectively, showing, in its threading position, a single needle having a tip-split eye and usable in FIG. 1 and other Figures;

FIG. 8 is a fragmentary detail view, in front elevation, of one form of the split-tip needle shown in FIGS. 6, 7;

FIG. 9 is a plan view, in section, taken on line 9--9 of FIG. 8;

FIG. 10 is a fragmentary detail view, in front elevation, of another form of the split-tip needle shown in FIGS. 6, 7;

FIG. 11 is a plan view, in section, taken on line 11-11 of FIG. 10;

FIGS. 12 and 13 are detail views, in front and side elevation respectively, showing the needle of FIGS. 6, 7 in its retracted position to form a pile loop;

FIG. 14 schematically shows an arrangement for bonding the underside bit-ends of loop pile shown in FIGS. 12, 13 and other Figures;

FIGS. 15 and 16 show, in perspective, split-tip needle means suited for making loop pile or U-pile, each needleeye being opened and closed by linear motion (FIG. 15) or arcuate motion (FIG. 16);

FIGS. 17, 18 and 19 are explantory Figures referred to in discussion of a modification of FIG. 16;

FIGS. 20, 21 and 22 are, explanatory Figures corresponding with FIGS. 17-19 with arcuate movement of the other needle-shank member;

FIGS. 23, 24 and 25 are explanatory Figures corresponding with FIGS. 17-19 but with arcuate movement of both needle-shank members;

FIG. 26 shows a multi-station array with common linear eye-control means for needles of split-tip type shown in FIG. 15;

FIGS. 27, 28, 29 are front elevational views of another. form of split-tip needle whose eye may be opened of the for threading (FIG. 27), closed for tufting (FIG. 28), and opened for release of a loop tuft (FIG. 29);

FIGS. 30 and 31 are front elevational views of another form of split-tip needle whose normally closed eye (FIG. 30) may be opened (FIG. 31) for threading and/or release of a loop tuft by a rotatable cam;

FIG. 32 shows, in section, various suitable shapes for the rotatable cam of FIG. 30;

FIG. 33 schematically and partly in section illustrates a tufting station using a reciprocable split-eye needle for making loop-tufts from a continuous strand by which it is threaded in each cycle of reciprocation;

SUMMARY OF THE INVENTION In accordance with one aspect of the invention, the tufting needles are of split-eye type having two shank members which form an elongated eye which can be opened at or near the needle tip under control of cam means which engages either or both shank members. In some forms of these split-eye needles used to apply bits as U-tufting, the needle-eye may be opened to facilitate threading; in some forms of these split-eye needles used to apply bits as loop-tufting, the needle eyes are opened for release of a tuft loop; in some forms of these spliteye needles used to apply bits as U-and/or loop-tufting or to apply a continuous strand as a series of loop tufts, the needle eyes may be opened both for threading and for release of loop-tufts: in still another form, the needle-eye is opened for threading and closed to expel a loop-tuft whether formed from a bit or a length of continuous strand. The, split-eye needles may be ganged withclosed-eye needles in various arrangement to form hybrid tufting.

The invention further resides in features of construction, combination and arrangement hereinafter described and claimed.

DETAILED DESCRIPTION Referring to FIG..1, the basic mechanism associated with an individual tufting station 10 comprises a dual needle 11, a rotary cutter-bar/anvil arrangement 12 and a gas-flow transport means 13. The backing L, of burlap, woven or non-woven plastic or fabric, or other web of backing material is advanced step-by-step by a web feed and guide system 14 including the rolls 15A,15B. It is, of course, to be understood that for manufacture of tufted products, such as carpets, rugs, drapes, tapestries, upholsteringyfabrics, wall and automobile interior coverings, and the like, the tufting machine comprises a multiplicity of such stations whose needles may be attached to a common needle bar 8.

The dual needle 11 is reciprocated by means including the needle bar cam 16 on a one-time shaft 17 of the tufting machine. Upon completion of a tufting stroke, the dual needle 11 is in its uppermost or retracted position (FIG. 3) for which it is in the clear well above the backing L. The stripper bar 36 (FIG. 1) holds the backing L down while needle 11 is moving upwardly through the backing to form a U-tuft, as later described. While the needle is retracted, the backing L is advanced one step in the direction of the feathered arrow (FIG. 3). As the needle 11 descends: toward its threading position (FIG. I), the tip ends of the needle pierce the now stationary backing L and pass into the bit-delivery end or bit-loading station of the pneumatic transport means 13, in order to bring botheyes of the dual needle 11 into alignment with the passage 19 of the pneumatic transport system.

With certainty to insure threading for various sizes and compositions of the strand S of tufting material, each needle element 18 of the dual needle 11 may have separable shank or leg components 18A,18B (FIG. 2). Normally, the lower free ends (FIG. 4) of legs 18A,18B of each needle 18 are in position to form an elongated closed eye 9. Preferably, and as shown, the lower free end of the longer leg 18A is hook-shaped to form the tip T of the needle and the bottom of the needle eye 9.

At the bit-loading or threading position, the needle legs 18A,18B are spread apart (FIG. 2) in order that the now open or enlarged eye 9 is able, with certainty, to receive and pass the leading end of a strand bit B as propelled from the bit-cutting mechanism 12 via the gas-flow transport structure 13 (FIG. 1). An arrangement for effecting such temporary widening of the nee- I dle eye 9 comprises a cam or wedge which, in this modification, extends into or through the eye 9 and is normally clear of the legs 18A,18B (FIG. 4). Suitably below the top of the eye formed by them, the inner or adjacent faces of the legs 18A,18B are shaped to form converging cam-surfaces 21U,21U. As the needle moves from its retracted position (FIG. 4) to its bitloading or threading position (FIG. 2), the wedge 20 is engaged by these cam-surfaces 21U of the legs 18A,]8B. In consequence, the lower portions of both legs are displaced outwardly, thus widening or opening the eye 9 near the needle tip to afford desired clearance for an incoming bit of tufting material. As the loaded double needle 11 moves upwardly towards the retracted position (FIGS. 3, 4), the camp-surfaces 21U,21U of both needle elements leave the wedge cam 20, thus permitting the lower ends of both pairs of legs l 8A,l8B to return to their normal position, consequently closing the eyes 9 before the hook end of leg 18A passes upwardly through the backing L to apply a bit (FIGS. 3, 4) as a U-tuft. Preferably, and as shown, a slight clearance or gap is provided at the lowermost end of leg 188 (FIG. 4) to prevent clamping of any tendrils of a bit as the eye closes.

The mechanism 12 for feeding the strand S from a supplyspool SS (FIG. 1) and for cutting bits B therefrom comprises a pair of rolls or discs 22,23 coupled for rotation in opposite directions. In the particular construction shown in FIG. 1, the upper roll 22 is provided with a set of projecting knives 24A et seq. spaced about the periphery of the roll in order to form a rotary cutter bar as well as a feed roll. The lower roll may be provided with recesses or grooves 25A et seq. which serve as anvils for the knives 24A et seq. Thus, the lower roll 23 serves both as a rotary anvil as well as a feed roll. The grooves 25A et seq. (FIG. 1) are of suitable shape, for example, curvilinear, in turn to cooperate with the knives 24A et seq. (FIG. 1) in cutting a bit and controlling the leading end of strand S.

The rolls 22,23 turn in unison in opposite directions, as indicated by the arrows, and are driven by any suitable means (not shown) in timed relation to the reciprocating needle 11. For the position of rolls 22,23 shown in FIG. 1, the lowermost knife 243 has just completed severance of the trailing end of a bit B whose leading end was cut by knife 24A in the preceding cycle of reciprocation of the needle. Before the needle again returns to its bit-loading position (FIGS. 1,2), the new leading end of strand S is fed by rolls 22,23 to project into the inlet end of the transport passage 19. When the needle 11 has again returned to the bit-loading position shown in FIG. 1, the next knife 24C of cutter bar 22 cooperates with the next groove 25C of the rotary anvil 23 to cut another measured bit from the leading end of strand S.

In turn, each detected bit is propelled by air or other suitable gas along passage 19 and passes endwise through the eyes 9 of the dual needle 11 until its leading end is arrested by stop 26 beyond the needle. The stop 26 may be positioned in order that the loaded bit, as threaded into the needle, extends substantially equally on both sides of dual needle 11 (FIG. 1), or alternatively may be made to extend unequally on both sides of the needle. The propulsion of a bit from the strand-severing arrangement 12 is effected by flow of air or other gas from the bit-receiving end of passage 19 to and beyond the confined region into which the needle 1 1 is inserted for loading. As shown, the stop 26 may have a bore 19A which serves as a continuation of passage 19 for flow of air. However, a barrier, such as the end constriction shown, at or near the inlet end of passage 19A provides the bit-arresting function of stop 26. For pneumatic transport of the bits in passage 19, an above-atmospheric pressure source may be connected to that passage upstream of the needle or a below-atmospheric pressure source may be connected to passage 19 downstream of the needle. For various reasons, it is preferred that the bit be transported by air flowing to a below-atmospheric pressure source downstream of the needle-loading zone of passage 19. For such purpose, the outlet end of passage 19A of stop 26 has a fitting for connection, via tube 28, to a suction pump or other source (not shown). Such suction pump may be connected to passage 19 beyond the needle 1 1 in other ways, such as via a manifold common to the outlet ends of all passages 19 of the tuft-applying stations. For economy of air or other gas, its flow may be controlled by valve means 28V timed to open as the strand end is being fed and cut and to close after positioning of a bit at the threading station.

Each needle 11 may remain at rest in the bit-loading position for a time sufficient to permit pneumatic transport of a bit from the strand-severing arrangement 12 and for threading of the transported bit as positioned by stop 26 into the needle. This Down-dwell of the needle 1 1 (FIG. 1) may be predetermined by the dwell sector 16D of the needle-bar cam 16. In the particular construction shown by way of example, the dwell sector is about 45, which affords sufficient time for bit-transport and threading not only for one measured length of bit but for a substantial range of measured bitlengths which require corresponding different peripheral spacings of the cutter-bar knives and different settings of bit-stop 26. In general, the phasing of cam 16 with respect to the rotary cutter bar and anvil arrangement is such that the shortest bit is cut at, or just after, the beginning of the Down-dwell, and the length of the dwell sector 16D is sufficient to afford the required transport and bit-threading time for the longest bit whose severance occurs later in the Down-dwell period of the needle cycle.

At this point, it may also be noted that the cam 16 has a second dwell sector 16U (FIG. 3) which provides that the needle 11 remains in full retracted position for a substantial fraction of the needle-bar cycle in order to afford a longer time in the needle cycle for indexing of the backing. The dwell sector 16U may be about 90 in extent. I

A modified form 26A of the bit-stop 26 of FIG. 1 is shown in FIG. 5. In this modification, which can be incorporated in the basic mechanism of FIG. 1, the bit passage beginning just beyond the needle 11 (FIG. 5) comprises the internal bore 19A of a deformable resilient tube 28A of natural or synthetic rubber, other elastomeric material, or the like. The tube 28A extends beyond two squeezing or clamping members 29A,29B. The upper clamping member 298 of rectangular, round or other cross-section, may be stationary. The lower clamping member is movable and may be a cam or eccentric 29A rotatable about a fixed axis to select the distance from needle 11 at which the bit-passage 19A is constricted by the squeeze members 29A,29B sufficiently to prevent further movement of a bit' as transported by a flow of air. The bit is stopped by such constriction, but the air may continue its flow. With this form of stop, there is reduced tendency for the bits to bounce back from the stop. This type of constriction serves both as a stop and a brake. In the particular construction shown in FIG. 5, the movable squeezing member 29A may have three lobes and may be moved or indexed to corresponding angular position by correspondingly shifting the location of the constriction of tube 28A to suit measured bits cut to different lengths. Also, the entire cam mechanism may be shifted, if desired, horizontally for one or more other ranges of minimum to maximum strand-lengths.

In the particular arrangement shown in FIG. 1 by way of example, the cutter bar 22 is shown as having a set of eight knives equally spaced at 45 intervals. To provide the needle 11 with a bit each time it arrives at bitloading position, the roll 22 is moved one-eighth revolution per cycle of the needle. To cut shorter or longer measured bits, different cutter bars 22 with correspondingly greater or lesser number of knives per set may be used with a corresponding change of the extent of angular motion of roll 22 per needle cycle.

With all previously herein described forms of the present invention, the bits of tufting material as applied to the backing L form a tufted product having freeended or U-pile whereas those now described may form a tufted product having looped pile.

I For the modification shown in FIGS. 6-14, the needle 118 for each station is a single needle of split eye construction differing from that shown in FIGS. 1, 2 in that the needle eye is opened when the need;e is clear of the backing L rather than opened when the needle is in threading position and is provided with camsurface 21L,21L for that purpose. The tip-forming ends of needle legs 118A,118B may abut (FIGS. 8,9) or may be complementarity notched or recessed to overlap (FIGS. 10,11) when in normal closed-eye position. In either case, the needle l18is of split-tip type rather than of the split-side type (FIG. 2).

As shown in FIGS. 6,7, the needle 118 has penetrated the backing L to bring its closed eye into alignment with the passage 19 of the pneumatic transport system 13. For this threading position of needle 118, the wedge 120, which extends between the legs 1 18A,l 18B of the needle, is clear of the cam-surface 21L of the needle legs (FIG. 7). Consequently, the lower ends of legs 118A,118B jointly form the tip end of the needle and the lower end of the now closed needleeye (FIG. 7).; Asthe needle is moved upwardly toward the retracted position shown in IN FIGS. 12,13, the intermediate portion of the threaded bit B is pulled through the backing L to form a loop-tuft BL, leaving the end portions of the bit on the underside of the backing L. By the time the needle 118 reaches its. fully retracted position, the wedge 120 has engaged the cam-surface 21L of the needle legs 118A,118B, thus to spread them I clear of the pile loop (FIG. 13). The height of the looptuft BL may be varied in production of a sculptured article by changing the vertical position of the normally stationary wedge 120, thus to open the needle eye sooner or later in the loop-forming stroke of the needle for any preselected needle cam. The bit-length and the position of stop 26 may be correspondingly varied to insure formation of a loop of desired height and without excessive length of the bit-ends on the underside of the backing L. While the needle legs are spread apart (FIG. 13), the backing L is advanced (FIG. 14) to carry the looped tuft BL out of the now open eye of needle I18.

Suitably beyond the needle station, the bit-ends extending from the underside of backing L .may be bonded or locked to the backing by any of various known techniques. For example, a tacky liquid latex compound may be brushed or rolled onto the backing L nad the tufted bit-ends, or for quicker setting, hot polyethylene or other thermoplastic cement may be spread, sprayed or rolled onto the underside of the backing L and the projecting bit-ends. In the latter case, a blast of cold air, for example, may be blown on the applied surface to chill the cement. Specifically, and as shown in' FIG. 14, the bit-ends may be turned against the underside of the backing L by a cold or hot pressure roll after the bonding cement has been applied. Alternatively, the roll 85 may also serve as a feed or guide roll for web or strip 86 comprising or faced with a bonding material which may be activated prior to its engagement with the backing L and the underside ends of the pile loops: in this case, the bonded material becomes a substrate of the tufted product.

In the previously described modifications of the spliteye needle, the two spaced legs or shank elements extend from an integral connecting portion of the needle shank and may be biased by the resiliency inherent to such fork construction to their closed-eye or open-eye position. In the modifications shown in FIGS. 15 and 16, the two legs 718A,7l8B of each needle respectively extend from two mounting elements, either or both of which may be moved to open the eye for threading, or for loop-tuft release, or for both. A single needle of such split-tip construction suffices if only loop-tufts are to be made at the corresponding station: two such needles per station provide for loop-tufting, U-tufting or both.

In FIG. 15, the legs 7l8A,7l8B of each needle respect ively extend from the individual mounting members A,1 10B and are moved linearly with respect to each other to open and close the elongated needle eye formed by them. Proper alignment of the legs may be maintained by guide means exemplified by rods [11 during relative linear motion, of the. leg mounts 110A,] 108 as effected by any suitable means. For example, the two leg mounts for an individual tufting station may be forced, as by spring means not shown, to the closed-eye position of the legs 718A,7 18B and may be moved to open-eye position by suitablyplaced rotatable cam means which in another form is schematically shown in FIGS. 30 and 31. Also as shown in FIG. 26, the leg mounts 110A for the needle legs 718A of different tufting stations may be attached to the needle bar 8 and the leg mounts 110B for the associated needle legs 718B may be attached to the common linearly reciprocable guide bar 112 supported from the needle bar 8, as by the mounts 110A. By suitable means not shown, the bar 112 may be moved to and from the position shown in FIG. 26 to open and close the eyes of all split-eye needles of the station. The linear motion of the bar 112 may be timed to open the needle eyes for threading, for release of loop tufts, or for both. It is immaterial which leg of the pairs of needle legs is attached to bar 112 for movement relative to the other leg.

In FIG. 16, the legs 718A,718B of each needle respectively extend from the individual mounting members 110C,110D and are moved arcuately with respect to each other to open and close the elongated needle eye formed by them. Proper alignment of the legs may be maintained by thrust bearings, not shown, during relative arcuate motion of the leg mounts by any suitable means. For example, the two leg mounts 110C,1l0D for a tufting station may be forced, as by spring means, to closed-eye position of the needle legs 718A,718B and both may be moved away from each other to open-eye position by suitably placed rotatable cam means extending between the legs, and which in another form is schematically shown in FIGS. 30,31. Instead of rotating both mounts, either mount may be stationary and the other rotatable.

In both FIGS. and 16, the individual needles are of split-tip type in which the eye is open for threading, for loop release, or both, and is closed for passing through the backing. In FIGS. 17-19, the needle is of split-side type in which the eye is open for threading and closed for loop-tuft release. However, the needle legs 618A,618B of FIGS. 17-19 are not joined by an integral shank portion but respectively extend from individual mounts 110C,110D, both reciprocable with the needle bar (not shown). In addition, the mount 110D is rotatably supported for rocking motion by any suitable means not shown. The mount 110D is moved in clockwise direction, suitably before, or when, the needle is in threading position (FIG. 17) to swing the leg 618B toward leg 618A, thus to open the needle eye to receive a bit B of tufting material (FIG. 18): the mount 110D is moved in counterclockwise direction, suitably after the needle tip T has cleared the backing, to swing the leg 618B away iron leg 618A, thus to sweep the loop tuft BL out of the shallow tip-groove of leg 618A (FIG. 19).

In FIGS. 20-22, the mount 110D reciprocates linearly with the needle bar (not shown) but has no menate motion whereas the mount 110C, also reciproc'able with the needle bar, is additionally rocked back and forth by any suitable means not shown. The mount 110C is moved in counterclockwise direction, suitably before, or when, the needle is in threading position (FIG. 20) to swing the leg 618A toward leg 6188, thus to open the needle eye to receive a bit B of tuftingmaterial (FIG. 21): the mount 110C is moved in clockwise direction, suitably after the needle tip T has cleared the backing L to swing the leg 618A away from the leg 6188 so that the latter sweeps the loop-tuft BL out of the shallow tip-groove of leg (FIG. 22).

In FIGS. 23-25, both of the mounts 110C,1l0D are rotatably supported from the needle bar. The mounts C,110D are moved respectively in counterclockwise and clockwise directions suitably before, or when, the needle is in threading position (FIG. 23) to swing the legs toward one another, thus to open the needle eye to receive a bit B ('FIG. 24): the mounts 110C,110D are rotated in the reverse directions, suitably after the needle tip T has cleared the backing L to swing the legs 618A,6l8B away from one another, thus to sweep the tuft-loop BL out of the shallow tip-groove of leg 618A.

In all of FIGS. 15; 16; 17-19; 20-22; 24H-24J, the height of the tuft loop formed from the bit may be varied by changing the time, in the up-stroke of the needle bar, at which the loop BL is expelled (FIGS. 19, 20, 25) from the needle by the arcuate motion of one or the other, or both, of the leg mounts 110C,110D. In all of such Figures, a single needle per tufting station suffices if only loop-tufts are to be formed: two such needles per station provide for loop-tufting, or U-tufting, or both.

In all of the preceding forms of the invention, the split-eye needle there shown may be replaced by a spliteye needle 411 shown in FIGS. 27-29 whose eye may be opened in one position for threading, or in another position opened for release of a looped tuft, or opened for both of those positions. Such substitution may be made, for example, in any of the dual-needle modifications of FIGS. 1-5; l5; 16; 17; 20; 21; and in any of the single-needle modifications of FIGS. 6, 12; 16; 17; 20; 21. In other words, the split-eye needle 411 may be used to make open-end or U-tufts or loop-tufts from discrete bits of tufting as explained in discussion of the preceding modifications. As will be explained in discussion of FIG. 33, the needle 411 may also be used in individual tufting stations of a modified form of conventional tufting machine to form loop-tufts from continuous strands of tufting material, which loops, or any portion of them, may be subsequently out if desired.

Referring to FIGS. 27-29, the needle 411 has a split shank with legs 418A,418B. The inner faces of the legs 418A,418B are each provided with two spaced wedge engagable or cam surfaces 21U,21L. As the empty needle 411 approaches the backing, its cam-surfaces 21L,21L clear the double wedge 420; therefore, the free ends of legs 418A,418B engate each other to form the piercing point of the needle. When the needle tip T penetrates the backing L, the upper pair of camsurfaces 2lU,2lU is engaged by cam or wedge 420, thus to spread the legs 418A,418B (FIG. 27) and open the needle eye 9 for threading by a bit B to be pneumatically fed thereto as previously described, or for threading by a bit length ofa continuous strand S as later discussed. Before the needle 411 moves in reverse direction through the backing L, the wedge 420 disengages the cam-surfaces 21U,21U, thus permitting the free ends of legs 418A,418B to reengage and close the needle eye 9 (FIG. 28). The eye remains closed as the needle 411 moves in reverse direction to pull the bit B through the backing L to form a loop-tuft. During the return stroke (or loop-forming stroke) of needle 411, wedge 420 moves up to the correct position for the cam-surfaces 21L,21L to be engaged to open the needle eye for release of the looped-tuft (FIG. 29) when the loop is a desired height corresponding with such position of the wedge. The positioning of wedge 420 may be effected by any suitable means (not shown) operated in timed relation to the needle bar. Before the empty needle 411 is again moved to pierce the backing L in the next tufting cycle, the wedge 420 is moved from engagement with cam-surfaces 21L,21L of the split-shank to position shown in FIG. 28.

The split-tip needle 811 (FIGS. 30,31) is similar to split-tip needle 41] (FIGS. 27-29), but simpler to manufacture because having no cam-surfaces 21U or 21L. In this modification, the elongated eye formed by the needle legs or shank elements 81 1A,81 1B is opened for threading, or for loop-tuft release, or both, by a rotatable cam 448 which reciprocates linearly with the needle bar. At desired times in the cycle of reciprocation of the needle, the cam, 448 is movedangularly by suitable means not shown to spread the needle legs apart (FIG. 30), thus to open the eye through the needle tip T, and is again moved angularly to permit the needle legs to come together, thus to close the eye and reform the needle tip (FIG. 31). The eye-control cam 448 may, as shown in FIGS. 30,31, be a flat-sided oval, but may be of any other suitable shape including those shown in FIG. 32.

In FIG. 33, the reciprocating needle 411, or equivalent, repeatedly cooperates with wedge cam 420, or

equivalent, to form successive tuft loops SL from a continuous strand S of tufting material mechanically fed to the needle from the supply spool SS or other source. The strand-feed mechanism 413 comprises the nip rolls 101,102 and the guide roll 100. While the needle is moving in direction to form a tuft-loop SL and while the backing L is being indexed to move the loop from the needle, the nip roll 102 is moved upwardly for cooperation with nip roll 101 is feeding of strand S to the needle-threading station shown and inpart defined by plate 104. As shown, the plate 104 extends from guide roll 100 below the backing L and is apertured to clear the tip of the needle when in threading position with the eye below backing L. It is to be noted that the tufting needle is rethreaded by-the strand in each cycle and that the loop tuft is freed from the needle in each cycle during or upon completion of the tufting stroke.

The plate 104 may extend across the entire width of the machine. The rolls 100,101 may be grooved, preferably less than the strand diameter, to maintain separation between the strands for adjacent tufting stations. The pairs of plates 108 guide the strands to their threading positions. The reciprocating movement of the feed roll 102 between its feed and non-feed positions may be effected by any suitable timed means including air-motors 103, cams (not shown) or the like.

Preferably and as shown in FIG. 33, the last-formed loop may be prevented from being shortened, or pulled out, while needle 411 is forming a loop by provision of a pair of clamping plates 105M,105S .then pressing against the length of strand S which extends along the underside of backing L between these two loops. The clamping pressure is released during indexing of the backing L by its feed roll 15B and is subsequently reapplied in the next needle cycle. An array of interleaved clamping plates 105M,105S may extend across the entire width of the tufting machine and a slight movement of movable plates 105M between clamping and release positions effected by any suitably timed actuating means including cam 106, an air-motor, or the like.

If desired, and as shown for example in FIG. 33, the leading edge ofa new length ofbacking L may be sewn to a lead strip LS with the temporary and removable stitching holding the leading ends of the strands S, as

extending forwardly from the loop SL of the firstformed row, against the underside of the backing.

With the arrangement shown in FIG. 33, the looptufts SL successively formed from a strand S fed to a particular tufting station may be of the same or different height depending upon the positioning of wedge 420 to open the needle eye after it has passed through the backing L in its loop-forming stroke. The positioning of wedge 420 of the tufting machine may be programmed to produce a sculptured effect of the tufted rug or other product.

However, with the arrangement shown in FIG. 33, all of the loops SL successively formed at a particular tufting station are of the same color or characteristic of the strand S fed from the associated source SS. By providing the tufting stations with individual multistrand selectors any desired color pattern may be reproduced in the tufted product. The loop heiglhts may be the same or different as discussed above. With any of such multistrand selectors, as used in combination with the basic arrangement of FIG. 33, each of the individual cutter bars associated with the multi-strand selector may have but a single knife and is programmed to sever a continuous strand only when the pattern demands a change in color, i.e., the selection of another strand.

In both FIG. 33, the needles are to substantial extent relieved of the load and wear incident, in conventional tufting machines, to feeding of yarn to the needles and formation of tufts therefrom: the yam is also subjected to less tension in the yarn-feeding and tufting. In consequence, the production capability of the tufting machine over a substantial period of time is markedly enhanced because of lesser down-time for repairing yarn breakage. and for needle replacement because of wear or breakage. In FIG. 33, the single split needle may be replaced by two split needles to form two loop tufts per cycle of reciprocation of the needle bar.

What is claimed is:

l. A tufting needle having spaced shank members which normally form a closed eye, the inner face of at least one of said shank members having two camengaging surfaces at different distances from the tip portion of the needle, and

cam means extending between said shank members to open said eye upon engagement with either of said surfaces.

2. A tufting needle having spaced shank members normally forming a closed eye, the inner faces of said shank members having two pairs of cam-engaging surfaces at different distances from the tip portion of the needle, and

cam means extending between said shank members to open said eye upon engagement with either of said pairs of surfaces.

3. In combination, a tufting needle having spaced shank members with free ends normally in proximity to form a closed eye, said shanks having complementary structure at their free ends to form a piercing end and a yarn receiving eye with the needles closed and with the needles opened a passageway for release of yarn outwardly of said piercing end,

cammeans extending between said shank members,

and

means for rotating said cam means to control the movement of the shank members between the eye opening and eye closing positions.

4. In a tufting machine, the combination of a tufting needle assembly comprising a plurality of needles each having a body portion and each having cooperating shanks with complementary structure to form a piercing end and a yarn receiving eye with the needles closed and with the needles opened a passageway for release of yarn outwardly of said piercing end, said shanks having a length exceeding the length of the tufting stroke, means disposed between said shanks for controlling the opening and closing of said eye, means for moving the needles through the backing, and means for operating said controlling means for producing (1) opening of said eye when on one side of said backing, (2) reclosing said eye before movement through said backing, and (3) again opening said eye when on the opposite side of said backing.

5. In a tufting machine, the combination of a tufting needle assembly comprising a plurality of needles for piercing a backing, means for moving said needles through the backing, each said needle having complementary shanks to form said piercing end and a yarn receiving eye with the needles closed and with the needles opened a passageway for release of yarn outwardly of said piercing end, and a mechanical control associated with each needle to control the opening and the closing of the needles so that the needles can receive and release yarn during a tufting operation.

6. For use in a tufting machine, the combination of a'tufting needle assembly comprising a plurality of needles for piercing a backing, means for moving said needles through the backing, each said needle having complementary shanks to form a piercing end and a yarn receiving eye between said shanks for receiving yarn when on one side of said backing, and means operable when said needles are on the opposite side of said backing for moving one shank relative to its other shank to open said eye to release a tufted yarn.

7. For use in a tufting machine, a tufting needle assembly comprising a plurality of needles each having a body portion and cooperating complementary shanks forming an end for piercing a backing and further defining an internal eye between said shanks means for moving said needles through the backing, at leist one of said shanks being movable apart from the other shank by rotary action imparted to one of said shanks to control the opening and the closing of said needles so that said needles can receive and release yarn during a tufting operation.

8. For use in a tufting machine, a tufting needle assembly comprising a plurality of needles each having a body portion and cooperating shanks and forming an end for piercing a backing and further in part defining an internal eye between said shanks, means for moving the needles through the backing, said needle assembly further including mounting means connected to said cooperating shanks by which at least one of said shanks is movable apart from the other shank to control the opening and closing of the needles so that the needles can receive and release yarn during a tufting operation.

9. For use in a tufting machine, a tufting needle assembly comprising a plurality of needles each having a body portion and cooperating dual shanks, which form an internal eye, means for moving the needles through a backing, said assembly further including dual elongated rotatable mounting members to weich one shank of each needle is mounted to while the other shank of each needle is mounted to the other member, means for rotating one of said mounting members relative to the other for opening and closing the eyes of the plurality of needles to allow yarn to be admitted'into said eyes on one side of a backing layer before a tufting stroke and released on the opposite side of the backing after said stroke.

10. For use in a tufting machine, a tufting needle assembly comprising a plurality of needles each having a body portion and cooperating dual shanks, which form an internal eye, means for moving the needles through a backing, said assembly further including dual elongated mounting members to which one shank of each needle is respectively mounted while the other shank of each needle is mounted to the other member, means for linearly moving at least one of said mounting members from and toward the other to relatively displace said corresponding shanks linearly one from the other to cause the eyes of the plurality of needles to open and close in concert to allow yarn to be admitted into said eyes on one side of a backing layer before a tufting stroke and released on the opposite side of the backing after said stroke.

11. For use in a tufting machine a tufting needle assembly comprising a plurality of needles each having a body portion and cooperating complementary shanks which form a piercing end and a yarn receiving eye with the needles closed and with the needles opened a passageway for release of yarn outwardly of said piercing end, means for moving the needles through a backing, said assembly further including cam means with said shanks being profiled to cooperate with said cam means to cause the eyes of the plurality of needles to open and close in concert so that the needles can receive and release yarn during a tufting operation.

12. For use in a tufting machine, a tufting needle assembly comprising a plurality of split-shank tufting needles, the cooperating shanks of each needle defining an internal thread receiving eye, at least one of said shanks having a thread-engaging shoulder on the internal eye surface and further having a material piercing tip, the two shanks of each needle being connected one to each of two mounting members, said mounting members being relatively movable so that one shank of eachneedle is relatively movable towards and away from the other between a first position in which the eye is closed and a second position in which the eye is open.

13. The tufting needle assembly of claim 12 including means for rotating at least one of said two mounting members so that said corresponding shanks are displaced at the tip end one fromthe other as the eye is opened.

14. The tufting needle assembly of claim 12 including means for linearly moving at least one of said twomounting members one from the other so that at least one of each of said corresponding shanks is movable in linear fashion toward and away from the other corresponding shank.

15. For use in a tufting machine, a tufting needle assembly comprising a plurality of split-shank tufting needles, having complementary shanks which form a piercing end and a yarn receiving eye with the needles closed and with the needles opened a passageway for release of yarn outwardly of said piercing end, the inwardly directed faces of the shanks being profiled to cooperate with a stationary eye-opening and eyeclosing cam, a shank of each of said needles being movable under the control of said cam toward and away from its associated shank between a first position in which the eye is closed and a second position in which the eye is open.

16. For use in a tufting machine, a tufting needle assembly comprising a plurality of split-shank tufting needies, a rotatable eye-opening cam, the cooperating shank of each needle being an integral split-shank component of complementary structure to form a piercing end, said shanks together defining an internal threadreceiving eye, each shank being profiled to cooperate with said rotatable eye-opening cam disposed between said shanks to engage and cooperate with the inwardly directed faces of the shanks so that a shank of each needle is movable towards and away from its other shank between a first position in which the eye is closed and a second position in which the eye is open.

17. For use in a tufting machine, a tufting needle assembly comprising a plurality of split-shank tufting needles arranged in pairs, the cooperating shanks of each needle having complementary structure at their ends to form a piercing end and a yarn receiving eye with the needles closed and with the needles opened a passageway for release of yarn outwardly of said piercing end,

a shank of each needle being each movable towards and away from its other shank between a first position in which the eye is closed and a second position in which the eye is open.

18. For use in a tufting machine, a tufting needle assembly comprising a plurality of split-shank tufting needles, and an eye-opening cam, the cooperating shanks of each needle being an integral split-shank component and together defining an internal thread-receiving eye, each of said inwardly directed faces of the shanks being profiled to project inwardly in two places to cooperate with said eye-opening cam, a shank of each needle being relatively movable away from its other shank when a first of said profiled shank surfaces coact with the stationary eye-opening cam, said shank being movable toward its other shank when said first-profiled surfaces are moved past said cam, said shank being movable away from its other shank when said second of said profiled surfaces coacts with the cam so as said needle is reciprocated relative to said cam, said eye is opened to admit a strand of yarn, closed to tuft said strand and opened to release said strand.

"313 um'rlcp SlA'li'lS PATENT owidm (9/ CEI K'LIFICATE OF CQRRECTION y f N ,715 Dat d September ll, 1973 I 0 Invcntofls) Abram N. Snanel It is certified that error appears in the above-identified patent: and that: said Letters Patent; are hereby corrected as shown below:

Column 1, line 32, delete "details" and insert "detail".

Column 4, line 7, delete "detected" and insert "detached".

Column 5, line 49, delete "need;e" and insert. "needle";

-line. 52, delete ."surface" and insertl'surfa'ces";

V line 63, delete "cam-surface" and insert "cam-surfaces" Column 6, line 6, delete "cam-surface" and insert "cam-surfaces" l ..line 26, delete "nad" and insert "and" Column 7, line 49, delete "iron" and insert '"from";

line 65, after "leg" insert "618A" Column 8, line ll, delete. "24H-24J".. and insert ,"23-25";

line 45, delete "engate" and insert "engage".

Co'lumn9, line 32, delete "is" and. insert "in". Column l0,line 26, delete "both" w Column 11, line 43 delete leist" and insert "least": i ,line 65, delete "weich" and insert "which" 1' Signed and s'ealedthis, 19th day of March l97) (SEAL) Attest: 4

EDWABD M.FLETCHER,JR. s. MARSHALL DANN Attesmng Officer Commissioner of' Patents 

1. A tufting needle having spaced shank members which normally form a closed eye, the inner face of at least one of said shank members having two cam-engaging surfaces at different distances from the tip portion of the needle, and cam means extending between said shank members to open said eye upon engagement with either of said surfaces.
 2. A tufting needle having spaced shank members normally forming a closed eye, the inner faces of said shank members having two pairs of cam-engaging surfaces at different distances from the tip portion of the needle, and cam means extending between said shank members to open said eye upon engagement with either of said pairs of surfaces.
 3. In combination, a tufting needle having spaced shank members with free ends normally in proximity to form a closed eye, said shanks having complementary structure at their free ends to form a piercing end and a yarn receiving eye with the needles closed and with the needles opened a passageway for release of yarn outwardly of said piercing end, cam means extending between said shank members, and means for rotating said cam means to control the movement Of the shank members between the eye opening and eye closing positions.
 4. In a tufting machine, the combination of a tufting needle assembly comprising a plurality of needles each having a body portion and each having cooperating shanks with complementary structure to form a piercing end and a yarn receiving eye with the needles closed and with the needles opened a passageway for release of yarn outwardly of said piercing end, said shanks having a length exceeding the length of the tufting stroke, means disposed between said shanks for controlling the opening and closing of said eye, means for moving the needles through the backing, and means for operating said controlling means for producing (1) opening of said eye when on one side of said backing, (2) reclosing said eye before movement through said backing, and (3) again opening said eye when on the opposite side of said backing.
 5. In a tufting machine, the combination of a tufting needle assembly comprising a plurality of needles for piercing a backing, means for moving said needles through the backing, each said needle having complementary shanks to form said piercing end and a yarn receiving eye with the needles closed and with the needles opened a passageway for release of yarn outwardly of said piercing end, and a mechanical control associated with each needle to control the opening and the closing of the needles so that the needles can receive and release yarn during a tufting operation.
 6. For use in a tufting machine, the combination of a tufting needle assembly comprising a plurality of needles for piercing a backing, means for moving said needles through the backing, each said needle having complementary shanks to form a piercing end and a yarn receiving eye between said shanks for receiving yarn when on one side of said backing, and means operable when said needles are on the opposite side of said backing for moving one shank relative to its other shank to open said eye to release a tufted yarn.
 7. For use in a tufting machine, a tufting needle assembly comprising a plurality of needles each having a body portion and cooperating complementary shanks forming an end for piercing a backing and further defining an internal eye between said shanks means for moving said needles through the backing, at leist one of said shanks being movable apart from the other shank by rotary action imparted to one of said shanks to control the opening and the closing of said needles so that said needles can receive and release yarn during a tufting operation.
 8. For use in a tufting machine, a tufting needle assembly comprising a plurality of needles each having a body portion and cooperating shanks and forming an end for piercing a backing and further in part defining an internal eye between said shanks, means for moving the needles through the backing, said needle assembly further including mounting means connected to said cooperating shanks by which at least one of said shanks is movable apart from the other shank to control the opening and closing of the needles so that the needles can receive and release yarn during a tufting operation.
 9. For use in a tufting machine, a tufting needle assembly comprising a plurality of needles each having a body portion and cooperating dual shanks, which form an internal eye, means for moving the needles through a backing, said assembly further including dual elongated rotatable mounting members to weich one shank of each needle is mounted to while the other shank of each needle is mounted to the other member, means for rotating one of said mounting members relative to the other for opening and closing the eyes of the plurality of needles to allow yarn to be admitted into said eyes on one side of a backing layer before a tufting stroke and released on the opposite side of the backing after said stroke.
 10. For use in a tufting machine, a tufting needle assembly comprising a plurality of needles each having a body portion and cooperating dual shankS, which form an internal eye, means for moving the needles through a backing, said assembly further including dual elongated mounting members to which one shank of each needle is respectively mounted while the other shank of each needle is mounted to the other member, means for linearly moving at least one of said mounting members from and toward the other to relatively displace said corresponding shanks linearly one from the other to cause the eyes of the plurality of needles to open and close in concert to allow yarn to be admitted into said eyes on one side of a backing layer before a tufting stroke and released on the opposite side of the backing after said stroke.
 11. For use in a tufting machine a tufting needle assembly comprising a plurality of needles each having a body portion and cooperating complementary shanks which form a piercing end and a yarn receiving eye with the needles closed and with the needles opened a passageway for release of yarn outwardly of said piercing end, means for moving the needles through a backing, said assembly further including cam means with said shanks being profiled to cooperate with said cam means to cause the eyes of the plurality of needles to open and close in concert so that the needles can receive and release yarn during a tufting operation.
 12. For use in a tufting machine, a tufting needle assembly comprising a plurality of split-shank tufting needles, the cooperating shanks of each needle defining an internal thread receiving eye, at least one of said shanks having a thread-engaging shoulder on the internal eye surface and further having a material piercing tip, the two shanks of each needle being connected one to each of two mounting members, said mounting members being relatively movable so that one shank of each needle is relatively movable towards and away from the other between a first position in which the eye is closed and a second position in which the eye is open.
 13. The tufting needle assembly of claim 12 including means for rotating at least one of said two mounting members so that said corresponding shanks are displaced at the tip end one from the other as the eye is opened.
 14. The tufting needle assembly of claim 12 including means for linearly moving at least one of said two-mounting members one from the other so that at least one of each of said corresponding shanks is movable in linear fashion toward and away from the other corresponding shank.
 15. For use in a tufting machine, a tufting needle assembly comprising a plurality of split-shank tufting needles, having complementary shanks which form a piercing end and a yarn receiving eye with the needles closed and with the needles opened a passageway for release of yarn outwardly of said piercing end, the inwardly directed faces of the shanks being profiled to cooperate with a stationary eye-opening and eye-closing cam, a shank of each of said needles being movable under the control of said cam toward and away from its associated shank between a first position in which the eye is closed and a second position in which the eye is open.
 16. For use in a tufting machine, a tufting needle assembly comprising a plurality of split-shank tufting needles, a rotatable eye-opening cam, the cooperating shank of each needle being an integral split-shank component of complementary structure to form a piercing end, said shanks together defining an internal thread-receiving eye, each shank being profiled to cooperate with said rotatable eye-opening cam disposed between said shanks to engage and cooperate with the inwardly directed faces of the shanks so that a shank of each needle is movable towards and away from its other shank between a first position in which the eye is closed and a second position in which the eye is open.
 17. For use in a tufting machine, a tufting needle assembly comprising a plurality of split-shank tufting needles arranged in pairs, the cooperating shanks of each needle having complementary structure at their ends to form a piercing enD and a yarn receiving eye with the needles closed and with the needles opened a passageway for release of yarn outwardly of said piercing end, a shank of each needle being each movable towards and away from its other shank between a first position in which the eye is closed and a second position in which the eye is open.
 18. For use in a tufting machine, a tufting needle assembly comprising a plurality of split-shank tufting needles, and an eye-opening cam, the cooperating shanks of each needle being an integral split-shank component and together defining an internal thread-receiving eye, each of said inwardly directed faces of the shanks being profiled to project inwardly in two places to cooperate with said eye-opening cam, a shank of each needle being relatively movable away from its other shank when a first of said profiled shank surfaces coact with the stationary eye-opening cam, said shank being movable toward its other shank when said first-profiled surfaces are moved past said cam, said shank being movable away from its other shank when said second of said profiled surfaces coacts with the cam so as said needle is reciprocated relative to said cam, said eye is opened to admit a strand of yarn, closed to tuft said strand and opened to release said strand. 